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Title: Right up Egon's alley

JT Metalworks - May 17, 2010 06:57 AM (GMT)
Since I'm plumb out of machinable wax, I took the next cheapest material I had on hand to try out my contours.

This intake is a particular pain in the heine due to how the hole spacing is different for every pair of holes, and slightly different for every runner hole. If you just duplicated the spacing of the first two, you end up about .030 out by the other end.

To make matters even more "fun," the car's original intake is poorly molded plastic and has even more variation in it, so much so, that the bolt holes are off from one another and VW accounted for this with rubber bushings on the mounting bolts. I'm thinking it warped over the years, but without a CMM there was no good way to see the pattern (the plastic manifold only has one bolt per runner in a staggered pattern across the middle ports). It just wouldn't work out on paper and I wasn't about to accept .010 slop in a master print just to make it work. Fortunately, my customer was able to score the aluminum one cheap, because he wasn't interested in pulling the head so I could get good dimensions.

Rather than risking making something that wouldn't fit, I banged out part of the program in wood for a test pattern.

user posted image

So now that I have my port contours and hole locations right, I can start working on the 3D transitions to the runners.

Franzę - May 17, 2010 07:10 AM (GMT)
You know Egon could have banged that out in 4 to 6 weeks from treetrunk to finished product using only his chainsaw. He could have held a ╝" tolerance too right after he converted inches to Canahodian metric.

He even would have grown his own tree!

JT Metalworks - May 17, 2010 07:58 AM (GMT)
That one took 6 minutes, but only cause I didn't ramp up the feed due to only having it screwed down on the 4 corners and the wood split as it was.

Hell, I didn't even resurface the 2x6 I had in the vises left over from the last job. This wood stuff makes really great sub plates for one-off junk. I can even tap it with a forming tap and use my 3/8" set of te-co toe clamps.

JT Metalworks - May 18, 2010 03:21 AM (GMT)
Aluminum version took a bit longer than 6 minutes. :)

Gasket side:
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Runner side:
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Franzę - May 18, 2010 03:57 AM (GMT)
Not too bad lookin for a wetnosed schoolkid messin around in shop class.

Just a suggestion here, the pictures would look a lot better if you got some of that lovely pink carpet Marko uses to photograph everything on and used that. That pink rug just shouts special when you see it.

I bet Jack could make it faster onhis ironworker!

JT Metalworks - May 18, 2010 04:24 AM (GMT)
You don't like my dumpster sourced welding throne?

I even have spare casters for that thing from the other one I took specifically for parts.

There's an outfit in the industrial park down the road from me who's got the contract for one of the big local banks branch furniture. They throw out anything that's not completely presentable, so if this one ever sparks off, I'll just go nab another one.

I even got a whole tub full of brass 5/16-18 threaded inserts that I don't think they were intending to dispose of. :D My guess is they came out of signage that they were breaking up and someone forgot to bring them inside before quitting time that day.

Franzę - May 18, 2010 04:59 AM (GMT)
As a company azzet it's a fine one, probably even too good for you to plant yerself on since you ain't anything akin to a banker.

As a photoshoot backdrop, Marko's carpet sets the standard.

I'm still codgitating on employing one of my hydraulic cosmetology chairs for a welding stool. Thing is I got a whole dollar invested in each one of them, and every time I testsit one I nap out.

JT Metalworks - May 18, 2010 05:11 AM (GMT)
Bah, I don't need no stinking carpet.

Franzę - May 18, 2010 05:25 AM (GMT)
JT, you don't need the whole floor covered with carpet, just carve a 3 or 4 foot square out of some lovely carpet sitting onthe curb waiting for pickup, drag it home, and hang it up outside just in case of fleas.

When you need the photo backup you haul the carpet in, lay it on the welding bench take the picture and then you haul the carpet back out.
That background carpet lets you raise the price considerable, might be high as 7 or 9 dollars a unit more.

Now if you'd just get the pencil sharpener machine going I have a brilliant product I shoplifted that would allow dang near every car clown to build his own DIY sodablaster that actually worked. You could probably make so much money you could send Junior off to military school if he don't sweep the shop up.

JT Metalworks - May 18, 2010 05:37 AM (GMT)
I need to get the short list of customer crap out of here before I worry about the pencil sharpener. I'm also still at an impasse about where to stuff the motor-generator. You'd think after a year I'd know where I wanted to park it, but I don't. :( Part of that problem is I'm not sure the automatics are going to remain parked where they are.

egon - May 19, 2010 02:41 PM (GMT)
the pictures would look a lot better if you got some of that lovely pink carpet

Bah, I don't need no stinking carpet.

Well look, you don't have to cut a square out of the living room one you know. Just go to a carpet dealer and get a leftover piece from a job.

JT Metalworks - May 21, 2010 07:20 PM (GMT)
user posted image

user posted image


Franzę - May 22, 2010 01:17 AM (GMT)
That's not too awful bad for a kid learning to run a hot glue gun JT.

Sure would look a lot more marketable against a Pink Plush Background though for eyeball appeal unless you can find a broad with big boobs and borrow a wheelchair.

egon - May 24, 2010 10:53 AM (GMT)
Naw, not a pink carpet Franz!

That beauty needs a stand in the living room for placing on and getting admired.

Next thing we know theres a gallery being set up.

JT Metalworks - May 24, 2010 05:31 PM (GMT)
It's getting sand blasted and painted by the customer (who's already got it). If I kept it here, I wouldn't get paid.

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